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Introduction on Scale Up Fine Chemicals : From Lab to Plant Site

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Title: Introduction on Scale Up Fine Chemicals : From Lab to Plant Site


1
Introduction on Scale UpFine Chemicals From
Lab to Plant Site
  • By
  • Wiratni, PhD
  • Gadjah Mada University
  • Yogyakarta - Indonesia

2
Evolution of chemical engineering
Global trend in chemical industries
Mass production
Specialties/fine chemicals
Focused on CONVERSION
Emphasized on PROPERTIES
Conventional Chemical Engineering
New view in chemical engineering Product
Engineering
3
Chemical industries in developing countries
OPERATIONS
PROCESS ENGINEERS
DESIGNERS
LICENCES
NET PROFIT
4
Flexibility for changes
International chemical giants (DuPont, BASF, Dow)
Chemical plants in developing countries
Natural resources
Commoditization
STRONG R D
LICENSE!
Specialties
5
Price scale
Product engineering
Fine chemicals
Chemical engineering
Crude products
Raw materials
6
Position of Biotechnology
  • Highly specific in producing particular compounds
    ? important role in fine chemical production
  • Characteristics
  • - higher level of uncertainty
  • - decreasing performance of microorganisms

7
Bioprocess Engineering
Raw material (substrate)
Microorganism/enzyme
PURIFICATION UNITS
BIOREACTOR
WASTE
Fermentation Broth
DOWNSTREAM PROCESSING
Product
8
Downstream processing
  • Very costly can take up to 70 of total
    investment
  • Very important in bioprocess as it determines the
    specification of product (purity,
    physical/chemical characteristics, etc.)

9
Example of Bioproduct
  • Poly-?-Hydroxy-Butirate (PHB)
  • Biodegradable polymer with high biocompatibility
    for medical purposes
  • Produced intracellularly by microorganisms (e.g.
    Alcaligenes euthrophus), using sugar compounds as
    substrate

10
Nature of PHB
  • Characteristics
  • Amount of PHB accumulated
  • Degree of crystallinity
  • Physical/mechanical properties
  • Purity
  • VERY SENSITIVE TO PROCESS CONDITIONS

11
Problems
  • PHB is carbon storage for the microorganisms
    they will accumulate it when they have plenty of
    food, and will consume it when they are lack of
    food
  • Must determine
  • When is the optimum harvesting time??

12
Problems
  • PHB is biodegradable, and so it is susceptible to
    oxidation, chlorination, etc. that may lead to
    decreasing molecular weight.
  • Must determine
  • What chemicals to be used in purification
    process?
  • What temperature does not destructive to PHB?

13
Problems
  • If the previous questions have been answered
    through laboratory experiments, you may define
    optimum conditions (composition of substrate,
    temperature, pH, etc) for PHB production.
  • Bigger problem
  • Do those optimum conditions for Erlenmeyer flask
    still hold for 100 L fermentor?

14
Menghitung kebutuhan power
Power number
Reynold number
15
Example Making homogeneous solutions
LAB SCALE
COMMERCIAL SCALE
(IDEAL)
(NON-IDEAL)
16
Why studying scale-up techniques?
17
Producing Fine Chemicals
  • The technology is not matured yet
  • Very specific for each particular product
  • Very costly if buy licensed technology for each
    product
  • Companies must have very strong RD with two fold
    tasks
  • 1. developing new products
  • 2. designing commercial units (SCALE-UP)

18
Scale Up in Essential Oil Production
Laboratory experiment
Pilot scale
Commercial scale
SCALE UP PROCESS
19
Route to Commercialization
LABORATORY SCALE
TRIAL AND ERROR
MATHEMATICAL MODELS
VERIFICATION IN PILOT PLANT
ERRORS
COMMERCIAL PRODUCTION
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